Clean Air America

7 Superior Drive Rome, GA 30161

Problem:

Mando Corporation is a tier 1 auto parts manufacturer which required a solution to coolant mist from their series of 22 CNC machining centers. The customer operates with very little downtime and required a mist collection system that would withstand the long production cycles involved in being a tier-1 auto supplier. Several vendors were considered in the initial evaluation with competing systems requiring manual maintenance, offline draining, and frequent filter changes.

Clean Air America, Inc. presented a proposal with a system that was capable of ventilation of several machines at one time with a centralized ductwork system. The unit had to be capable of mounting on a custom fabricated mezzanine and serviceable with maximum filter life. The plant objective was to maintain an air quality that met an oil mist standard well below 1.0 mg/m3, one to three year filter life, maintained airflow throughout operation, and online draining for coolant reclaim.

Solution:

Clean Air America, Inc. proposed two customized central ZeroMist Model OM-7200 units, each which is capable of providing 7,200 CFM of airflow within a single housing. Each unit was outfitted with six (6) coalescing first stage fiber bed filters, six (6) coalescing second stage fiber bed filters, six (6) HEPA-grade final filters, a full set of pressure gauges for each filter stage, and 20HP TEFC energy efficient direct drive motors. VFD controls were also selected for additional energy savings and programmed for slow accelerated start & stops, pressure drop adjustments, and paired with a Dwyer pressure sensor. Additional provisions on this system included an automatic pump back system with motor, float controls, and holding tank that allows the collected coolant to be drained back to the centralized coolant filtration system. The custom unit was coordinated with the customer’s designed mezzanine for adequate service access and placement that minimized valuable production floor space. The ductwork was designed in accordance with SMACNA and ACGIH standards to a tapered, balanced, and liquid-tight design and slight slope to allow for drainage during shut-down period back into the mist collector inlet plenum.

Clean Air America handled the job fully turnkey, designing the system, manufacturing the equipment, and executing the installation. The final result yielded a fully-automated mist collection system that was capable of reducing energy costs up to 50%, filter life averaging 2-3 years, continuous draining capabilities, and consistent airflow throughout operation to maintain a negative pressure in each CNC machining center. Equally as important, the ZeroMist solution puts Mando fully in compliance for current & future oil mist regulations.

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